Systems and methods for conditioning synthetic crude oil

Abstract

Systems and methods for conditioning synthetic crude oils are provided herein. The systems and methods described herein subject the synthetic crude to one or more process solutions to provide conditioned synthetic crude exhibiting, for example, a reduced TAN.

The invention claimed is: 
     
       1. A system for conditioning synthetic crude oil, the system comprising:
 a synthetic crude oil delivery system including a source of synthetic crude oil obtained by pyrolysis of one or more materials selected from polymer, plastic, and rubber materials; 
 a process solution delivery system configured to provide a caustic process solution having a pH of between about 8 and about 10; 
 a mixer positioned downstream of the synthetic crude oil delivery system and the process solution delivery system to receive and mix a first volume of the synthetic crude oil with a second volume of the process solution, the first volume of the synthetic crude oil being less than the second volume of the process solution; and 
 a separator positioned downstream of the mixer that receives the mixture of synthetic crude oil and process solution, wherein the separator is configured to provide separation of conditioned synthetic crude oil from the process solution. 
 
     
     
       2. The system of  claim 1 , wherein the process solution is aqueous solution comprising a soluble caustic selected from the group consisting of potassium hydroxide (KOH), calcium hydroxide (Ca(OH) 2 ), cesium hydroxide (CsOH), Barium hydroxide (Ba(OH) 2 ), sodium hydroxide (NaOH), strontium hydroxide (Sr(OH) 2 ), and lithium hydroxide (LiOH). 
     
     
       3. The system of  claim 2 , further comprising one or more pH sensors, wherein the pH sensors are positioned within the system to evaluate the pH of the process solution. 
     
     
       4. The system of  claim 3 , further comprising a caustic delivery system, wherein the caustic delivery system is configured to deliver additional caustic material to the process solution if the pH of the solution decreases below about 8. 
     
     
       5. The system of  claim 4 , wherein the one or more pH sensors are operatively associated with the caustic delivery system to assist in maintaining the PH of the process solution between about 8 and about 10. 
     
     
       6. The system of  claim 1 , wherein the separator comprises a separation tank including one or more diffuser assemblies and the mixture of synthetic crude oil and process solution are delivered to the separation tank through the one or more diffuser assemblies. 
     
     
       7. The system of  claim 6 , wherein the separator comprises a primary separation tank comprising one or more weirs. 
     
     
       8. The system of  claim 7 , wherein the separation tank comprises one or more diffuser assemblies and the mixture of synthetic crude oil and process solution are delivered to the primary separation tank through the one or more diffuser assemblies. 
     
     
       9. The system of  claim 6 , further comprising a process solution collection system configured to collect process solution separated from the synthetic crude oil. 
     
     
       10. The system of  claim 9 , wherein the process solution collection system comprises one or more pH sensors. 
     
     
       11. The system of  claim 10 , wherein the system further comprises a caustic delivery system and the one or more pH sensors are operatively associated with the caustic delivery system such that the caustic delivery system introduces additional caustic material into the separated process solution to bring the pH of the process solution up to a pH of between about 8 and about 10. 
     
     
       12. The system of  claim 11 , further comprising a synthetic crude flow rate monitor configured to assess the volume of synthetic crude oil delivered to the mixer. 
     
     
       13. The system of  claim 12 , further comprising a filtration system for removing solid particulates entrained within the synthetic crude oil, wherein the filtration system comprises filter media capable of capturing entrained particulates exhibiting a size selected from the group consisting of 500 μm or less, 200 μm or less, 100 μm or less, 50 μm or less, 25 μm or less, 10 μm or less, 5 μm or less, and 1 μm or less.